Interlocking flange and fastening system and method for securing together two panels

ABSTRACT

A flange component used to secure a first panel to a second panel including a first section to be affixed to the first panel and a second section to be affixed to the second panel. The second section is integrally formed with the first section, which has a length dimension that is longer than a length dimension of the second section forming first and second tabs. The second section of the flange component is integral to an intermediate section between the first and second tabs. The second tab is offset relative to the intermediate section and first tab whereby when the first section is attached to the first panel, a space is formed between the second tab and the first panel. A first tab of an adjacent flange component is inserted this space, and the second section protrudes from a periphery of the first panel for receiving the second panel.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. application Ser. No.13/435,451 filed Mar. 30, 2012, which claims the benefit of U.S.Provisional Application No. 61/469,961 filed Mar. 31, 2011, andincorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

The subject invention relates generally to fastening systems, methodsand/or fasteners that are used to fasten or secure together two panels.More specifically, the subject invention relates to such systems andmethods used to secure together two panels, such as panels of a cowling,for aircraft and/or automobiles.

Fasteners, such as those disclosed in U.S. Pat. Nos. 5,795,122 and5,716,180, and 7,997,843, and manufactured by SKYBOLT® located inLeesburg, Fla., are used to secure together two panels. Such fastenersgenerally include a receptacle that is mounted to the inner supportpanel and aligned with a hole in the outer panel or cowling, an optionalgrommet may be attached to the outer panel, and a stud that is insertedthrough the grommet (if installed), through both panels and into thereceptacle in which it is locked in position. These fasteners arecommonly referred to as “quarter turn” panel fasteners or blind threadedfasteners. Typically, these fasteners are used to secure two panelstogether that may overlap one another and have an integral flangecomponent for securing the two panels together.

However, a number of panels, used for example on aircrafts and racingvehicles or industrial applications, are designed to abut one another,and do not include adequate inner support flanges for supporting thereceptacles for quarter turn fasteners or threaded blind fasteners.Accordingly, a flange must be fabricated to fit the panels. Fabricationof such a flange can be extremely time consuming especially when thepanels have bends or curves. After a flange or a series of flangesections is fabricated to fit a panel, holes must be drilled in theflanges to accept the fastener receptacle. The spacing of receptacles,and consequently the holes in the panels, is dependant on obstacles suchas engine mounts or accessories. Locating or properly positioning theholes and drilling the holes are arduous processes.

Accordingly, a need exists for a part that can be used to adapt one ormore panels to include a flange to secure the two panels togetherwithout having to essentially fabricate the flange on site.

BRIEF DESCRIPTION OF THE INVENTION

An embodiment of the invention includes a flange component for securingtogether two panels wherein a plurality of the flange components areused in conjunction with a plurality of fasteners. The flange componentmay include a first section having an intermediate section disposedbetween and integrally connected to a first tab and a second tab,wherein the first section has a first length dimension and is capable ofbeing affixed to a first panel. The flange component also includes asecond section integrally connected with the intermediate section of thefirst section and having a second length dimension that is less than thefirst length dimension. In a preferred embodiment, the second sectionincludes at least one aperture for receiving a fastener that is capableof affixing the second section to the second panel. In addition, on afirst side of the component the intermediate section, first tab andsecond section of the flange component form a coextensive first surface,and the second tab forms a second surface that is offset relative to thefirst surface.

In this manner, when the flange component is attached to a panel with afirst side of the flange component facing the panel, a space is formedbetween the second tab and the panel. When a plurality of the flangecomponents are aligned side by side or end to end for attachment to thefirst panel, a first tab on a flange component is inserted in the spacebetween the second tab and second panel, the second section protrudesbeyond a periphery of the first panel for receiving the fastener andsecond panel.

In an embodiment in which quarter-turn fasteners or threaded blindfasteners, or any other fastener including a receptacle attached to thesecond section at the aperture, holes are formed in the second panel foralignment with the apertures and receptacle. If the panels are used tocover a part or object that has obstacles, it may be necessary to avoidcertain obstacles. In such a case, the first tab may be trimmed toshorten the distance between two adjacent receptacles and avoid anobstacle.

BRIEF DESCRIPTION OF THE DRAWINGS

A more particular description of the invention briefly described abovewill be rendered by reference to specific embodiments thereof that areillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered to be limiting of its scope, the invention will bedescribe and explained with additional specificity and detail throughthe use of the accompanying drawings.

FIG. 1 is an elevational view of a face or side of the flange component.

FIG. 2 is a perspective view of the flange component.

FIG. 3 is an elevational view of a side edge of an inventive flangecomponent.

FIG. 4 is a perspective view of a plurality of the flange componentsshown aligned side by side and having fastener receptacles installedthereon.

FIG. 5 is an elevational view of the face or side of the plurality ofthe flange components of FIG. 4.

FIG. 6 is an elevational view of the edges of a plurality of the flangecomponents of FIG. 4.

FIG. 7 is an elevational view of the flange component with a tab trimmedas may be necessary for installation.

FIG. 8 is a partial perspective view of a plurality of the flangecomponents installed on a first panel.

FIG. 9 is an expanded perspective view of the flange componentsinstalled on the first panel illustrated in FIG. 8.

FIG. 10 is a partial perspective of a second panel having been affixedto the flange components of FIG. 8.

FIG. 11 is an elevational view of an installed first flange componentand a second flange component positioned for installation.

FIG. 12 is a flowchart including steps in a method of securing togethertwo panels using the flange components described herein.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the embodiments consistent withthe invention, examples of which are illustrated in the accompanyingdrawings. Wherever possible, the same reference numerals are usedthroughout the drawings and refer to the same or like parts.

The present invention may be used in the assembly of a part thatincludes at least two panels secured in fixed relation to one another,wherein the panels have elongated edges that require multiple fastenersspaced apart along a respective edge of one or both of the panels.Accordingly, in an embodiment of the subject invention multiple flangecomponents are used to form a flange assembly to support the fastenersand secure the panels together. The term panel as used herein mayinclude a panel including a single panel section or multiple panelsections secured together to form a single panel.

With respect to FIG. 1-3, a flange component 10 is illustrated includinga first section 11 and a second section 12. The first section 11 isintended to be affixed to a first panel 15 (shown in FIG. 8-10) and thesecond section 12 is intended to be affixed to a second panel 26 (alsoshown in FIGS. 8-10). The second section 12 is configured to receive afastener 16 that includes a receptacle 17, grommet 18 and stud 19. Morespecifically, an aperture 23 is formed in the second section 12 forreceiving a fastener 6. Examples of fasteners that may be used inconjunction with a plurality of the flange components 10 are describedin U.S. Pat. Nos. 5,795,122, 5,716,180, and 7,997,843, thespecifications of which are incorporated herein by reference.

The first section 11 of the flange component 10 includes an intermediatesection 20 disposed between a first tab 13 and a second tab 14. That is,the first section 11 has a length dimension “1” that is greater than alength dimension “1” of the second section forming the tabs 13 and 14.The second tab 14 is disposed on the flange component 10 relative to theintermediate section 20 or relative to the first panel 15 so that thesecond tab 14 is spaced from the first panel 15 when the flangecomponent 10 is affixed to the panel 15. More specifically, as shown inFIG. 1, a face or surface 21 of the second tab 14 is offset relative toa face or surface 22 of the component 10 or intermediate section 20. Asshown in FIG. 11, when the flange component 10 is affixed. to a panel15, the offset positioning of the second tab 14 establishes a space orgap 28 between the panel 15 and the second tab 14. In this manner, thefirst tab 13 of an adjacent flange component 10 may be inserted into thespace 28.

The flange component 10 is preferably fabricated from a metal or metalalloy, such as aluminum or aluminum alloy, using stamping fabricationmachines and/or techniques or composite layup techniques. Accordingly,certain sections or parts of the component 10, including theintermediate section, first tabs 13 and second section 12 havesubstantially the same or equal thickness. In a preferred embodiment,the second tab 14 also has the same thickness. For example, for a flangecomponent used to install engine cowlings for aircraft and racingvehicles or industrial panels, the thickness of the component 10 may beabout 0.05 inches. Thus, the offset or distance the second surface 21 isoffset relative to the first surface 22 or the panel 15 is generallyequal to the thickness of the component 10. By dimensioning thecomponent 10 in this manner, the end to end alignment of the flangecomponents 10A-10D, as shown in FIG. 6, forms a substantially flush orcontinuous surface against a panel. In addition, the second tab 14preferably has a length dimension such that when the first tab 13 isinserted in the space 28, the second tab 14 covers the first tab 13 anda portion of the intermediate section 23; or, if the first tab 13 istrimmed as described below, the second tab 13 will cover a portion ofthe intermediate section 22.

With respect to FIGS. 2 and 3, and as described above, the flangecomponent 10 includes a second section 12 integrally formed with thefirst section 11. The second section 12 includes one or more aperturesfor attachment of the fastener 16 to the flange component 10 and thesecond panel 26, thereby securing a second panel 26 to the first panel15. In the embodiment shown, FIGS. 1, 6 and 9, the second section 12includes a first aperture 23 and two second apertures 24. The receptacle17 of the fastener 16 is generally aligned (preferably concentricallyaligned) with the first aperture 23 when the receptacle 17 is mounted toa second (or back) surface 25 of the flange component 10 or secondsection 12 of the flange component 10. The second apertures 24 mayreceive rivets for securing the receptacle 17 to the flange component10. In this manner, and as further shown in FIG. 10, the grommet 18 isdisposed within a hole on the second panel 26 and the aperture 23 of thesecond section 12, and the stud 19 is inserted through the grommet 18and into receptacle 17 and locked in position in a manner as set forthin the above cited '122 and '180 Patents to secure the second panel tothe flange component 10 and the first panel 15 and second panel 26. Asindicated above, some fasteners do not require grommets, so the use of agrommet is optional.

As shown in FIGS. 1 and 4-6, the length “1” of the first section 11,including the first and second tabs 13, 14 and intermediate section 20,is such that a center of the first aperture 23 and receptacle 17 arespaced apart a predetermined distance. By way of example, thepredetermined distance may be about 3.50 inches. However, duringinstallation of the flange components 10, fasteners 16 and panels, itmay be necessary to adjust the position of a fastener 16 relative to anadjacent fastener. With respect to a cowling for an aircraft that coversengine components, it may be necessary to adjust the relative positionof the fasteners 16 to avoid engine component parts. Accordingly, thefirst tab 13 may be trimmed to adjust the distance between respectivereceptacles 17 or fasteners 16 as shown in FIG. 7. Again with respect toHG. 4-6, the length of the first tabs 13 on a first and second flangecomponents 10A and 10B have been adjusted (or shortened) so that thedistance between respective fastener receptacles 17 may be, for example,3.00 inches as compared to the distance of respective receptacles 17mounted to flange components 10C and 10D, which distance is about 3.50inches.

In a method of securing a first panel to a second panel as outlined inthe flow chart of FIG. 12, a plurality of the above-described flangecomponents 10 are provided with a plurality of fasteners. (Step 30.) Atstep 32 the flange components are affixed to a first panel wherein thefirst section 11 of each flange component 10 is affixed to a first panelsuch that the second section 12 of each flange section protrudes from aperiphery 28 and is positioned to receive the second panel 26, asillustrated in FIGS. 8 and 9.

As noted above, obstacles such as engine mounts or engine components maybe present and the aperture 23 on the second section 12 of a flangecomponent 10 must be positioned relative to such obstacles so thereceptacle 17 of the fastener 16 can attached to the flange component10. Accordingly, the method may include step 30A which includespositioning the aperture 23 to avoid such obstacles, and if necessarytrimming the first tab 13 to appropriately position the aperture 23. Tothat end, at step 30B the flange components 10 are preferablytemporarily attached to the first panel 15 so that all the flangecomponents 10 are adequately positioned relative to one another and toexisting obstacles before more permanently affixing the flangecomponents 10 to the first panel 15. Rivets, driven through the panel 15and first sections 12 of respective flange components may be used toaffix the flange components 10 to the first panel 15.

At step 34, holes 29 are formed in the second panel, which holes arepositioned for alignment with the aperture 23 on respective flangecomponents 10 on the first panel 15, Formation of the holes 29 may beperformed by first marking the location for each hole 29 that is toreceive a grommet 18 (if needed) and stud 19. Then at step 36, thesecond panel 26 is affixed to the second section 12 of each of theflange components 10 by inserting the stud 19 into the receptacle 17,and turning it to a locked position, thereby securing the second panel26 in abutting relationship with the first panel 15. The step ofaffixing the second panel 26 includes positioning the second panel 26relative to the first panel 15, so that each hole 29 is aligned with acorresponding aperture 23.

While the preferred embodiments of the present invention have been shownand described herein, it will be obvious that such embodiments areprovided by way of example only and not of limitation. Numerousvariations, changes and substitutions will occur to those skilled in theart without departing from the teaching of the present invention.Accordingly, it is intended that the invention be interpreted within thefull spirit and scope of the appended claims.

1. A flange component for securing together two panels wherein aplurality of the flange components are used in conjunction with aplurality of fasteners, each fastener being secured to a respectiveflange component and one of the panels to secure a first panel to asecond panel, the flange component comprising: a first section includingan intermediate section disposed between and integrally connected to afirst tab and a second tab, wherein the first section has a first lengthdimension and is capable of being affixed to the first panel; a secondsection integrally connected with the intermediate section of the firstsection and having a second length dimension that is less than. thefirst length dimension and the second section having an aperture forreceiving a fastener to secure the second panel to the second sectionand relative to the first panel; wherein the first tab, intermediatesection and second section are co-planar and the first tab has athickness dimension, and the second tab is offset relative to theintermediate section a dimension that is substantially equal to thethickness of the first tab.
 2. The flange component of claim 1, whereina first side of the flange component faces the first and second panelswhen the first section is attached to the first panel and a second sideof the flange components faces away from the first and second panels,and the second tab is spaced apart from the first panel and a. first taband/or a portion of the intermediate section of an adjacent flangecomponent is disposed between the second tab and first panel.
 3. Theflange component of claim 2, wherein the intermediate section and thesecond section each has a thickness dimension that is substantiallyequal to the thickness dimension of the first tab.
 4. The flangecomponent of claim 1, wherein the first length dimension is set so thatthe apertures on the second section may be spaced apart a predetermineddistance when a flange component is installed on the first panel, andthe first tab is capable of being trimmed before installation to shortenthe predetermined distance.
 5. A flange component for securing togethertwo panels wherein a plurality of the flange components are used inconjunction with a plurality of fasteners, each fastener being securedto a respective flange component and one of the panels to secure a firstpanel to a second panel, the flange component comprising: a firstsection including an intermediate section disposed between andintegrally connected to a first tab and a second tab, wherein the firstsection has a first length dimension and is capable of being affixed tothe first panel; a second section integrally connected with theintermediate section of the first section and having a second lengthdimension that is less than the first length dimension and the secondsection having an aperture for receiving a fastener to secure the secondpanel to the second section and relative to the first panel; and,wherein on a first side of the flange component, the intermediatesection, first tab and second section of the flange component form acoextensive first surface, and the second tab forms a second surfacethat is offset relative to the first surface; and wherein a gap isformed between a panel and the first tab for receiving a second tab ofan adjacent flange component when the flange component is attached to apanel with the first side of the flange component facing the panel.